Académique Documents
Professionnel Documents
Culture Documents
February 2006
Systems Operation
Testing and Adjusting
3126B and 3126E Truck Engine
BKD1-Up (Engine)
G3E1-Up (Engine)
DPF1-Up (Engine)
1AJ1-Up (Engine)
8YL1-Up (Engine)
CKM1-Up (Engine)
CRP1-Up (Engine)
7AS1-Up (Engine)
8SZ1-Up (Engine)
9SZ1-Up (Engine)
i01658146
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3
Table of Contents
Table of Contents
Systems Operation Section
General Information ................................................ 4
Fuel System ........................................................... 7
Air Inlet and Exhaust System ............................... 36
Lubrication System .............................................. 40
Cooling System .................................................... 42
Basic Engine ......................................................... 45
Electrical System ................................................. 48
52
53
54
55
56
57
58
60
60
62
65
68
69
69
72
73
73
Lubrication System
Engine Oil Pressure - Test ....................................
Engine Oil Pump - Inspect ....................................
Excessive Bearing Wear - Inspect ........................
Excessive Engine Oil Consumption - Inspect .......
Increased Engine Oil Temperature - Inspect ........
76
79
79
79
80
Cooling System
Cooling System - Check (Overheating) ................
Cooling System - Inspect ......................................
Cooling System - Test ...........................................
Water Temperature Regulator - Test .....................
Water Pump - Test ................................................
81
83
84
88
89
Basic Engine
Piston Ring Groove - Inspect ................................
Connecting Rod Bearings - Inspect ......................
Main Bearings - Inspect ........................................
Cylinder Block - Inspect ........................................
Flywheel - Inspect .................................................
Flywheel Housing - Inspect ...................................
Vibration Damper - Check ....................................
Vibration Damper - Check ....................................
90
90
90
90
91
92
94
95
Electrical System
Battery - Test ......................................................... 97
Index Section
Index ................................................................... 104
4
Systems Operation Section
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General Information
SMCS Code: 1000
g00608514
Illustration 1
Right side view
(1) Lifting eye
(2) Engine crankcase breather
(3) Turbocharger
(4) Oil filler
(5) Water temperature regulator housing
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Systems Operation Section
g00608515
Illustration 2
Left side view
(11) Oil filler
(12) Lifting eye
(13) Fuel filter
6
Systems Operation Section
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NOTICE
Excessive ether (starting fluid) can cause piston and
ring damage. Use ether for cold weather starting purposes only.
Fuel System
SMCS Code: 1250
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Systems Operation Section
Introduction
Illustration 3
Diagram of components for the HEUI fuel system
g00457847
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Systems Operation Section
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Component Description
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Systems Operation Section
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Illustration 4
Low pressure fuel system
g00458217
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Systems Operation Section
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Illustration 5
Flow path of the injection actuation oil
(1) Unit injector hydraulic pump
(2) Oil flow to engine
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Oil from engine oil pump (4) supplies the needs of the
engine lubrication system. Also, oil from the engine
oil pump supplies the needs of unit injector hydraulic
pump (1) for the fuel system. The capacity of the
engine oil pump has been increased in order to meet
the additional flow requirement that is necessary.
Oil that is drawn from the sump is pressurized to the
lubrication system oil pressure by engine oil pump
(4). Oil flows from the engine oil pump through engine
oil cooler (5), through engine oil filter (3), and then to
the main oil gallery. A separate circuit from the main
oil gallery directs a portion of the lubrication oil in
order to supply unit injector hydraulic pump (1). A
steel tube on the left side of the engine connects the
main oil gallery with the inlet port of the unit injector
hydraulic pump.
Oil flows into the inlet port of unit injector hydraulic
pump (1) and the oil fills the pump reservoir. The
pump reservoir provides oil to the unit injector
hydraulic pump during start-up. Also, the pump
reservoir provides oil to the unit injector hydraulic
pump until the engine oil pump can increase
pressure.
The pump reservoir also provides makeup oil to the
high pressure oil passage in the cylinder head. When
the engine is off and the engine cools down, the oil
shrinks. A check valve in the pump allows oil to be
drawn from the pump reservoir in order to keep the
high pressure oil passage full.
Oil from the pump reservoir is pressurized in unit
injector hydraulic pump (1) and the oil is pushed out
of the outlet port of the pump under high pressure.
Oil then flows from the outlet port of the unit injector
hydraulic pump to the high pressure oil passage in
the cylinder head.
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Systems Operation Section
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Systems Operation Section
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g00458648
Illustration 6
Injection Actuation Oil Pressure Control
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Oil cooler
IAP sensor
Injectors
Fuel supply rail
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ECM (15)
IAP Control Valve (10)
IAP Sensor (6)
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16
Systems Operation Section
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g00295335
Illustration 7
Injection actuation pressure control valve
(1)
(2)
(3)
(4)
Drain port
Valve body
Control orifice
Spool chamber
(5)
(6)
(7)
(8)
Armature (5)
Valve spool (6)
Spool spring (7)
Poppet (9)
(9) Poppet
(10) Push pin
(11) Solenoid
Armature
Valve spool
Spool spring
Reduced pressure oil
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Systems Operation Section
g00295336
Illustration 8
Operation of the injection actuation pressure control valve (engine off)
(1) Pump outlet pressure (none)
(2) Current from ECM (none)
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Systems Operation Section
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g00295337
Illustration 9
Operation of the injection actuation pressure control valve (engine cranking)
(1) Pump outlet pressure
(2) Current from the ECM
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Systems Operation Section
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Systems Operation Section
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g00295338
Illustration 10
Operation of the injection actuation pressure control valve (running engine)
(1) Pump outlet pressure
(2) Current from the ECM
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Acceleration
Deceleration
Rapidly changing engine loads
Oil Flow for RUNNING ENGINE
When pump outlet pressure (1) enters the end of
the valve body, a small amount of oil flows into the
spool spring chamber through the control orifice in
the spool. The pressure in the spool spring chamber
is controlled by adjusting the force on the poppet
(4). Adjusting the force on the poppet (4) allows the
poppet to drain off some of the oil in the spool spring
chamber. The force on the poppet is controlled by the
strength of the magnetic field that is produced from
the electrical current from the ECM (2). The spool
responds to pressure changes in the spool spring
chamber. The spool changes positions in order to
balance the force on the spool. The spool tries to
make the force on the right side of the spool equal
to the force on the left side of the spool. The spool
position dictates the amount of the surface area of
the drain ports (3) that is open.
The open area of the drain port controls the amount
of oil that is drained off from the pump outlet. The
oil is drained off from the pump outlet in order to
maintain the desired actuation pressure. The process
of responding to pressure changes on either side of
the spool occurs so rapidly that the spool is held in a
partially open position and pump outlet pressure (1)
is closely controlled. The IAP Control Valve allows
infinitely variable control of pump outlet pressure (1)
between 6 MPa (870 psi) and 27.5 MPa (4000 psi).
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Systems Operation Section
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Systems Operation Section
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g00295359
Illustration 11
Component of the HEUI injector
(1)
(2)
(3)
(4)
(5)
Solenoid
Armature
Upper poppet seat
Poppet valve
Lower poppet seat
Solenoid (1)
Barrel (9)
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Systems Operation Section
Solenoid
Barrel
Poppet Valve
The poppet valve (4) has two positions which are
opened and closed. In the closed position, the poppet
is held on the lower poppet seat (5) by a spring. The
closed lower poppet seat prevents high pressure
actuation oil from entering the unit injector. The open
upper poppet seat (3) vents oil in the cavity that is
above the intensifier piston (6) to the atmosphere.
The oil is vented to the atmosphere through the
upper portion of the unit injector. In the open position,
the solenoid (1) is energized and the poppet valve
is lifted off the poppet valves lower seat. When the
poppet valve is lifted off the poppet valves lower
seat, the lower poppet seat opens allowing high
pressure actuation oil to enter the unit injector. When
the high pressure actuation oil enters the unit injector,
the high pressure actuation oil pushes on the top
of intensifier piston (6). The upper poppet seat (3)
of poppet valve (4) closes and upper poppet seat
(3) of poppet valve (4) blocks the path to the drain.
Blocking the path to the drain prevents the leakage of
high pressure actuation oil from the unit injector.
Intensifier Piston
The surface area of intensifier piston (6) is six times
larger than the surface area of plunger (7). This larger
surface area provides a multiplication of force. This
multiplication of force allows 27.5 MPa (4000 psi) of
actuation oil to produce 162 MPa (23500 psi) of fuel
injection pressure. When poppet valve (4) moves
away from lower poppet seat (5), high pressure
actuation oil enters the unit injector. When the high
pressure actuation oil enters the unit injector, the high
pressure actuation oil pushes on the top of intensifier
piston (6). Pressure rises on top of the intensifier
piston and the pressure pushes down on intensifier
piston (6) and plunger (7). The downward movement
of the plunger pressurizes the fuel in plunger cavity
(8). The pressurized fuel in the plunger cavity causes
nozzle assembly (10) to open. When the nozzle
assembly opens, the fuel delivery into the combustion
chamber begins. A large O-ring around the intensifier
piston separates the oil above the intensifier piston
from the fuel below the intensifier piston.
24
Systems Operation Section
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Nozzle Assembly
g00295360
Illustration 12
Nozzle assembly
(1) Inlet fill check ball
(2) Case
(3) Check
(4) Tip
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Pre-injection
Pilot injection
Delay
Main injection
End of injection
25
Systems Operation Section
26
Systems Operation Section
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Pre-Injection
g00295361
Illustration 13
HEUI injector (Pre-injection)
(1) Upper poppet seat (open position)
(2) Closed lower poppet seat
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Systems Operation Section
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Pilot Injection
g00295362
Illustration 14
HEUI injector (Pilot Injection)
(1) Upper poppet seat (closed position)
(2) Lower poppet seat (open position)
(A) Drain (atmosphere)
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Systems Operation Section
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Injection Delay
g00295363
Illustration 15
HEUI injector delay
(1) Upper poppet seat (closed position)
(2) Lower poppet seat (open position)
(A) Drain (atmosphere)
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32
Systems Operation Section
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Main Injection
g00295364
Illustration 16
HEUI injector (Main Injection)
(1) Upper poppet seat (closed position)
(2) Lower poppet seat (open position)
(A) Drain (atmosphere)
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End of Injection
g00295365
Illustration 17
HEUI injector (End of Injection)
(1) Upper poppet seat (open position)
(2) Lower poppet seat (closed position)
(A) Drain (atmosphere)
(B) Fuel supply pressure
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Systems Operation Section
Illustration 18
(1)
(2)
(3)
(4)
(5)
g00291751
Fuel filter
Fuel inlet
Fuel outlet
Fuel heater and water separator
Drain valve
36
Systems Operation Section
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i02275840
Exhaust manifold
Inlet air is pulled through the air cleaner. The inlet air
is then compressed and heated by the compressor
wheel of turbocharger (9) to about 150 C (300 F).
The inlet air is then pushed through air-to-air
aftercooler core (5) and the inlet air is moved to inlet
manifold (6). The temperature of the inlet air upon
entering inlet manifold (6) is about 43 C (110 F).
Cooling of the inlet air increases the combustion
efficiency. Increased combustion efficiency helps to
lower fuel consumption. Also, increased combustion
efficiency helps to increase horsepower output.
Aftercooler core (5) is a separate cooler core.
Aftercooler core (5) is installed in front of the core
(standard) of the engine radiator on the machine.
Air that is ambient temperature is moved across the
aftercooler core by the engine fan. This cools the
turbocharged inlet air.
From aftercooler core (5), the air is forced into the
cylinder head in order to fill the inlet ports. Air flow
from the inlet port into the cylinder is controlled by
inlet valves (1).
Illustration 19
g01139723
There are two inlet valves (1) and one exhaust valve
(2) for each cylinder. Inlet valves open when the
piston moves down on the inlet stroke. When the inlet
valves open, cooled compressed air from the inlet
port is pulled into the cylinder. The inlet valves close
and the piston begins to move up on the compression
stroke. The air in the cylinder is compressed. When
the piston is near the top of the compression stroke,
fuel is injected into the cylinder. The fuel mixes with
the air and combustion starts. During the power
stroke, the combustion force pushes the piston
downward. After the power stroke is complete, the
piston moves upward. This upward movement is
the exhaust stroke. During the exhaust stroke, the
exhaust valve opens, and the exhaust gases are
pushed through the exhaust port into the exhaust
manifold. After the piston completes the exhaust
stroke, the exhaust valve closes and the cycle starts
again. The complete cycle consists of four stages:
Inlet stroke
Compression stroke
Air cleaner
Power stroke
Turbocharger
Exhaust stroke
Aftercooler
Cylinder head
Valves and valve system components
Piston and cylinder
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37
Systems Operation Section
Turbocharger
Illustration 20
g01096602
Turbocharger
Illustration 21
g01139792
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Systems Operation Section
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Aid in starting
Aid in white smoke cleanup during start-up
Under the proper conditions, the Electronic Control
Module (ECM) turns on the electric heater. The
following conditions are evaluated prior to activating
the electric heater:
Illustration 22
g01107026
Rocker arms
Bridge
Spring
Pushrods
Exhaust valve
Inlet valves
Lifter
Camshaft lobe
System Components
The system of the air inlet heater consists of the
following basic components:
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Systems Operation Section
Illustration 23
g01139807
Location Of Components
(1)
(2)
(3)
(4)
(5)
(6)
The relay for the air inlet heater (1) is located on the
mounting bracket for the fuel filter. The relay turns
the 12 V heater ON and OFF in response to signals
from the ECM (6).
The air inlet heater (4) is a component of the air inlet
cover. The heater element has a ground strap (3) that
must be connected to the engine.
The ECM will then turn off the heater and the lamp.
When the operator attempts to start the engine prior
to the completion of preheat, the ECM proceeds into
the mode of cranking for heater control.
Mode of cranking
40
Systems Operation Section
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i01486056
Lubrication System
SMCS Code: 1300
Illustration 24
g00292659
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41
Systems Operation Section
Illustration 25
g00292660
Illustration 26
g00292662
42
Systems Operation Section
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Turbocharger cartridge
An oil cooling chamber is formed by the lip that is
forged at the top of the skirt of the piston and the
cavity that is behind the ring grooves in the crown.
Oil flow for the piston cooling jet enters the cooling
chamber through a drilled passage in the skirt. Oil
flow from the piston cooling jet returns to the engine
oil pan (27) through the clearance gap between the
crown and the skirt. Four holes that are drilled from
the piston oil ring groove to the interior of the piston
drain excess oil from the oil ring.
Illustration 27
g00292663
Cooling System
SMCS Code: 1350
This engine has a pressure type cooling system that
is equipped with a shunt line.
Valve mechanism
Camshaft bearing (12)
Crankshaft main bearings
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Systems Operation Section
Illustration 28
g01103269
Illustration 29
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Cylinder head
Water temperature regulator housing
Expansion tank
Bypass hose
Cylinder block
Oil cooler
Water pump
Radiator
Shunt line (expansion tank to water pump)
g01139885
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Systems Operation Section
The shunt line (9) extends from the top of the water
pump to an expansion tank. The shunt line must be
routed properly in order to avoid trapping any air.
By providing a constant flow of coolant to the water
pump, the shunt line keeps the water pump from
cavitation.
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Illustration 30
g01139902
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Systems Operation Section
Basic Engine
SMCS Code: 1200
One-Piece Pistons
The one-piece aluminum pistons have an iron band
for the compression ring. This helps to reduce wear
on the compression ring groove. The one-piece
piston has three rings:
Compression ring
Intermediate ring
Oil ring
All of the rings are located above the piston pin bore.
The compression ring is a Keystone ring. Keystone
rings have a tapered shape. The action of the ring
in the piston groove that is tapered helps prevent
seizure of the rings. Seizure of the rings is caused
by deposits of carbon. The intermediate ring is
rectangular with a sharp lower edge. The oil ring is a
standard type of ring or a conventional type of ring.
Oil returns to the crankcase through holes in the oil
ring groove.
Oil from the piston cooling jets sprays the underside
of the pistons. The spray lubricates the pistons and
the spray cools the pistons. The spray also improves
the pistons life and the spray also improves the
rings life.
46
Systems Operation Section
Two-Piece Pistons
The two-piece articulated piston consists of an alloy
forged steel crown that is connected to an aluminum
skirt by the piston pin. The two-piece articulated
piston has three rings:
Compression ring
Intermediate ring
Oil ring
All of the rings are located above the piston pin bore.
The compression ring is a Keystone ring. Keystone
rings have a tapered shape. The action of the ring
in the piston groove that is tapered helps prevent
seizure of the rings. Seizure of the rings is caused
by deposits of carbon. The intermediate ring is
rectangular with a sharp lower edge. The oil ring is a
standard type of ring or a conventional type of ring.
Oil returns to the crankcase through holes in the oil
ring groove.
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Oil pump
Camshaft
Hydraulic oil pump
Gear-driven air compressor
Power steering pump
In addition, belt pulleys on the front of the crankshaft
drive the following components:
Radiator fan
Water pump
Alternator
Refrigerant compressor
Hydrodynamic seals are used at both ends of the
crankshaft to control oil leakage. The hydrodynamic
grooves in the seal lip move lubrication oil back into
the crankcase as the crankshaft turns. The front
seal is located in the front housing. The rear seal is
installed in the flywheel housing.
Crankshaft
The crankshaft changes the combustion forces in the
cylinder into usable rotating torque which powers the
equipment. A vibration damper is used at the front of
the crankshaft to reduce torsional vibrations (twist on
the crankshaft) that can cause damage to the engine.
The crankshaft drives a group of gears on the front
of the engine. The gear group drives the following
devices:
Illustration 31
g00293227
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Systems Operation Section
Vibration Damper
Illustration 33
g00293230
Illustration 32
g00293231
Camshaft
The camshaft is located in the upper left side of the
cylinder block. The camshaft is driven by gears at
the front of the engine. Seven bearings support the
camshaft. A thrust plate is mounted between the
camshaft drive gear and a shoulder of the camshaft
in order to control the end play of the camshaft.
The camshaft is driven by an idler gear which is
driven by the crankshaft gear. The camshaft rotates in
the same direction as the crankshaft. The crankshaft
rotates in the counterclockwise direction when the
engine is viewed from the flywheel end of the engine.
There are timing marks on the crankshaft gear, the
idler gear, and the camshaft gear in order to ensure
the correct camshaft timing to the crankshaft for
proper valve operation.
As the camshaft turns, each lobe moves a lifter
assembly. There are two lifter assemblies for each
cylinder. Each lifter assembly moves a pushrod.
Each pushrod moves a valve (exhaust) or a set of
valves (inlet). The camshaft must be in time with
the crankshaft. The relation of the camshaft lobes
to the crankshaft position causes the valves in each
cylinder to operate at the correct time.
48
Systems Operation Section
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i01478239
Electrical System
SMCS Code: 1400; 1550; 1900
Grounding Practices
Proper grounding for the vehicle electrical system
and the engine electrical systems is necessary for
proper vehicle performance and reliability. Improper
grounding will result in unreliable electrical circuit
paths and uncontrolled electrical circuit paths.
Uncontrolled engine electrical circuit paths can result
in damage to main bearings, crankshaft bearing
journal surfaces, and aluminum components.
Uncontrolled electrical circuit paths can cause
electrical noise which may degrade the vehicle and
radio performance.
To ensure proper functioning of the vehicle and
engine electrical systems, an engine-to-frame ground
strap with a direct path to the battery must be used.
This may be provided by a starting motor ground, by
a frame to starting motor ground, or by a direct frame
to engine ground. An engine-to-frame ground strap
must be used in order to connect the grounding stud
of the engine to the frame of the vehicle and to the
negative battery post.
Illustration 35
g00769834
Illustration 34
Grounding Stud To Battery Ground ( )
g00769833
Charging circuit
Starting circuit
Low amperage circuit
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49
Systems Operation Section
Battery
Circuit breaker
Ammeter
Battery cables
The charging circuit is in operation when the engine
is running. An alternator generates electricity for the
charging circuit. A voltage regulator in the circuit
controls the electrical output in order to keep the
battery at full charge.
NOTICE
The disconnect switch, if equipped, must be in the ON
position in order to let the electrical system function.
There will be damage to some of the charging circuit
components if the engine is running with the disconnect switch in the OFF position.
Illustration 36
g00293544
(1) Brush holder. (2) Rear frame. (3) Rotor. (4) Stator. (5) Drive end
frame. (6) Fan assembly. (7) Slip rings. (8) Rectifier.
50
Systems Operation Section
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Illustration 37
Typical Solenoid
g00285112
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Systems Operation Section
Starting Motor
Illustration 38
g00293548
52
Testing and Adjusting Section
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Fuel System
6. Cut the old filter open with the 4C-5084 Oil Filter
Cutter. Inspect the filter for excess contamination.
Determine the source of the contamination. Make
the necessary repairs.
7. Service the primary fuel filter (if equipped).
Start Up Procedure
Note: Refer to Operation and Maintenance Manual,
Engine Starting in the Operation Section.
After work has been done on the fuel system,
consider the following precautions before you start
the engine. Make sure that you use this starting
procedure to start the engine only after the fuel
system has been worked on:
Illustration 39
g00296730
Fuel System
(1) Tube assembly (fuel filter to fuel supply passage)
(2) Tube assembly (fuel transfer pump to fuel filter)
(3) Pressure regulator
(4) Tube assembly (tank return line)
(5) Fuel inlet port (fuel transfer pump)
(6) Fuel filter
(7) Tube assembly
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53
Testing and Adjusting Section
i02486845
Elbows
Relief valves
Check valves
Observe the fuel flow during engine cranking.
Look for air bubbles in the fuel. If there is no fuel
in the sight gauge, prime the fuel system. Refer
to Testing and Adjusting, Fuel System - Prime
for more information. If the engine starts, check
for air in the fuel at varying engine speeds. When
possible, operate the engine under the conditions
which have been suspect of air in the fuel.
54
Testing and Adjusting Section
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Illustration 40
g01096678
i02276736
Tools Needed
Part
Number
Part Name
Quantity
1U-6602
or
9U-7400
Photo-Tachometer(1)
or
Multitach Tool Gp
(1)
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Testing and Adjusting Section
i02276920
Required Tools
Illustration 41
g00286276
Tool
Part
Number
Description
Qty
136-4632
Timing Pin
139-7063
Timing Pin
Adapter
5P-7305
Engine Turning
Tool
9U-6943
or
9U-7336
Housing As
178-8615
Engine Turning
Tool
Illustration 43
g01140081
g00296064
1U-6602 Photo-Tachometer
Illustration 44
Timing hole location (typical example)
g01140082
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Testing and Adjusting Section
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g01140087
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Fuel heaters
57
Testing and Adjusting Section
i01823195
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
If the engines fuel system is run dry, fill the fuel tank.
Then prime the fuel system in order to remove any
air bubbles from the system.
NOTICE
Do not loosen fuel lines at the fuel manifold. The
engine components may be damaged and/or loss of
priming pressure may occur when the fuel lines are
loosened.
Illustration 46
g00936682
Typical example
58
Testing and Adjusting Section
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Tools Needed
Part Number
Part Name
Quantity
1U-5470
or
198-4240
3Y-2888
Connector
3J-1907
O-Ring Seal
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
The 1U-5470 Engine Pressure Test Group or the
198-4240 Pressure Indicator Tool Gp can be used
in order to check the engines fuel pressures.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up fuel
spills immediately.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
Illustration 47
g01229712
Pressure indicators
Zero adjustment screw
Pressure indicator
Pressure tap
Pressure indicator
RENR1271-11
59
Testing and Adjusting Section
Illustration 48
g01229716
Illustration 49
g01229719
35 kPa (5 psi)
60
Testing and Adjusting Section
RENR1271-11
i02237153
i02277454
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
2. Remove the valve cover and look for broken parts.
Repair any broken parts or replace any broken
parts that are found. Inspect all wiring for the
solenoids. Look for loose connections. Also look
for frayed wires or broken wires. Ensure that the
connector for the unit injector solenoid is properly
connected. Perform a pull test on each of the
wires.
Illustration 50
g01134615
RENR1271-11
61
Testing and Adjusting Section
62
Testing and Adjusting Section
RENR1271-11
Required Tools
Part
Number
Part Name
Quantity
1U-5470
or
198-4240
Illustration 51
g00293196
Illustration 52
g00678913
Typical example
(1)
(2)
(3)
(4)
Turbocharger
Air Inlet Piping
Test location
Air cleaner
RENR1271-11
63
Testing and Adjusting Section
Exhaust Restriction
The muffler and converter will become extremly hot during engine operation. A hot muffler
and converter can cause serious burns. Allow
adaquate cooling time before working on or near
the muffler and converter.
Excessive idling can cause the catalytic
converter/muffler to plug. A plugged catalytic
converter/muffler will lead to an increase in
exhaust back pressure. Operating the engine in
extremely cold conditions may cause the catalytic
converter/muffler to plug. One indication of a plugged
catalytic converter/muffler is poor engine response.
If the engine is operated at low idle or at low load
for 24 or more consecutive hours, the engine should
be run at rated conditions for five to fifteen minutes.
Running the engine at rated conditions should clean
out the catalytic converter/muffler.
Required Tools
Part
Number
Part Name
Quantity
1U-5470
or
198-4240
Illustration 53
g00293196
64
Testing and Adjusting Section
RENR1271-11
Catalytic Converter/Muffler
Illustration 54
g00780838
Illustration 55
g00678914
Typical example
(1)
(2)
(3)
(4)
Catalytic converter/muffler
Test location
Exhaust piping
Turbocharger
RENR1271-11
65
Testing and Adjusting Section
i02494968
Turbocharger - Inspect
SMCS Code: 1052-040
g00894055
Inlet module
Catalyst module
Filter module
Outlet module
Test location
Tee fitting
Copper tubing
Thermocouple
66
Testing and Adjusting Section
RENR1271-11
RENR1271-11
67
Testing and Adjusting Section
Illustration 57
Typical Example
(1) Actuating Rod
(2) Canister
(3) Line
g00295815
68
Testing and Adjusting Section
RENR1271-11
Table 6
i02277487
Letter
Designation
kPa
psig
156
(23)
153
(22)
124
(18)
130
(19)
135
(20)
180
(26)
144
(21)
188
(27)
155
(23)
200
(29)
161
(23)
164
(24)
AG
148
(21)
Engine rating
Horsepower demand on the engine
High idle rpm
Height above sea level for engine operation
Inlet air restriction
Exhaust system restriction
NOTICE
If the high idle rpm or the engine rating is higher than
given in the Technical Marketing Information (TMI)
for the height above sea level at which the engine is
operated, there can be damage to engine or to turbocharger parts. Damage will result when increased
heat and/or friction due to the higher engine output
goes beyond the engine cooling and lubrication systems abilities.
Tools Needed
Part Number
1U-5470
or
198-4240
Part Description
Engine Pressure Group
or
Digital Pressure Indicator
Qty
1
RENR1271-11
69
Testing and Adjusting Section
i02100926
Tools Needed
Illustration 58
g00293196
Part
Number
Part Name
Quantity
164-3310
Infrared Thermometer
Aftercooler - Test
SMCS Code: 1063-081
Table 9
Required Tools
Illustration 59
g01140264
Part
Number
Part Name
Quantity
1U-5470
or
198-4240
FT-1984
FT-1438
Aftercooler Gp
(DYNAMOMETER TEST)
Visual Inspection
Hoses
Gasket joints
Air lines
70
Testing and Adjusting Section
RENR1271-11
Damage
Debris
Corrosion
Use a stainless steel brush to remove any corrosion.
Ensure that you use soap and water.
Note: When parts of the air-to-air aftercooler system
are repaired, a leak test is recommended. When
parts of the air-to-air aftercooler system are replaced,
a leak test is recommended.
The use of winter fronts or shutters is discouraged
with air-to-air aftercooled systems.
Illustration 60
g01134323
Low power
Low boost pressure
Black smoke
High exhaust temperature
RENR1271-11
NOTICE
Remove all air leaks from the system to prevent engine damage. In some operating conditions, the engine can pull a manifold vacuum for short periods of
time. A leak in the aftercooler or air lines can let dirt
and other foreign material into the engine and cause
rapid wear and/or damage to engine parts.
A large leak of the aftercooler core can often be
found by making a visual inspection. To check for
smaller leaks, use the following procedure:
71
Testing and Adjusting Section
Dust plug chains must be installed to the aftercooler core or to the radiator brackets to prevent
possible injury while you are testing. Do not stand
in front of the dust plugs while you are testing.
2. Install couplers (5) on each side of the aftercooler
core. Also, install dust plugs (7) and (8). These
items are included with the FT-1984 Aftercooler
Testing Group.
Note: Installation of additional hose clamps on the
hump hoses is recommended in order to prevent
the hoses from bulging while the aftercooler core is
being pressurized.
Illustration 61
g00581364
NOTICE
Do not use more than 240 kPa (35 psi) of air pressure
or damage to the aftercooler core can be the result.
72
Testing and Adjusting Section
Clean
Repair
Replacement
Turbocharger Failure
RENR1271-11
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
Table 10
Tools Needed
Part
Number
8T-2700
Part Name
Blowby/Air Flow Indicator
Quantity
1
Dynamometer Test
In hot ambient temperatures, chassis dynamometer
tests for models with an air-to-air aftercooler can
add a greater heat load to the jacket water cooling
system. Therefore, the jacket water cooling systems
temperature must be monitored. The following
measurements may also need a power correction
factor:
Illustration 62
g00286269
RENR1271-11
73
Testing and Adjusting Section
i01120286
Table 11
Compression - Test
Inlet Valves
Exhaust Valves
Valve Lash
Check
(Stopped
Engine)
0.38 0.08 mm
(0.015 0.003
inch)
0.64 0.08 mm
(0.025 0.003
inch)
TC
Compression
Stroke
1-2-4
1-3-5
TC Exhaust
Stroke(1)
3-5-6
2-4-6
Firing Order
i02277566
(1)
(2)
1-5-3-6-2-4(2)
Illustration 63
Cylinder and Valve Location
(A) Exhaust valve
(B) Inlet valves
g01105757
74
Testing and Adjusting Section
RENR1271-11
g01109236
Illustration 64
Table 12
Valve Lash
Valves
Dimension of Gauge
Inlet
Exhaust
(3)
TC Exhaust
Stroke(3)
Inlet Valves
Exhaust Valves
Valve lash
0.38 0.08 mm
(0.015 0.003
inch)
0.64 0.08 mm
(0.025 0.003
inch)
Cylinders
3-5-6
2-4-6
Table 13
TC
Compression
Stroke
Inlet Valves
Exhaust Valves
Valve lash
0.38 0.08 mm
(0.015 0.003
inch)
0.64 0.08 mm
(0.025 0.003
inch)
Cylinders
1-2-4
1-3-5
RENR1271-11
75
Testing and Adjusting Section
76
Testing and Adjusting Section
RENR1271-11
Lubrication System
i01565985
Illustration 65
g00296486
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened
component life.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Required Tools
Part Number
Part Name
Quantity
1U-5470
or
198-4240
8J-7844
Adapter Fitting
3K-0360
O-Ring Seal
4M-5317
or
5P-2720
Terminal Bushing
or
Probe Adapter
Illustration 66
g00864075
RENR1271-11
77
Testing and Adjusting Section
Illustration 67
g00866125
78
Testing and Adjusting Section
RENR1271-11
RENR1271-11
79
Testing and Adjusting Section
i01126690
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Engine oil pressure will be high if the engine oil
bypass valves become stuck in the closed position
and the engine oil flow is restricted. Foreign matter
in the engine oil system could be the cause for the
restriction of the oil flow and the movement of the
engine oil bypass valves. If the engine oil bypass
valves are stuck in the closed position, remove
each bypass valve and clean each bypass valve in
order to correct this problem. You must also clean
each bypass valve bore. Install new engine oil
filters. New engine oil filters will prevent more debris
from causing this problem. For information on the
repair of the engine oil filter bypass valve, refer to
Disassembly and Assembly, Engine Oil Filter Base Disassemble.
NOTICE
Caterpillar oil filters are built to Caterpillar specifications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
i01378651
stems
80
Testing and Adjusting Section
RENR1271-11
RENR1271-11
81
Testing and Adjusting Section
Cooling System
i01389751
82
Testing and Adjusting Section
RENR1271-11
RENR1271-11
83
Testing and Adjusting Section
i02209912
84
Testing and Adjusting Section
RENR1271-11
Tools Needed
Part
Number
Part Name
4C-6500
Digital Thermometer
8T-2700
9S-8140
Pressurizing Pump
9U-7400
or
1U-6602
Coolant/Battery Tester Gp
Illustration 68
g00921815
245-5829
Quantity
RENR1271-11
Illustration 69
85
Testing and Adjusting Section
g00876179
Illustration 71
g00286276
Illustration 70
g00286269
Illustration 72
g00296064
1U-6602 Photo-Tachometer
86
Testing and Adjusting Section
RENR1271-11
Tools Needed
Part
Number
9S-8140
Part Name
Pressurizing Pump
Quantity
1
Illustration 73
g00286369
Illustration 75
g01096114
g00439083
RENR1271-11
87
Testing and Adjusting Section
Filler cap
Seal
9S-8140
Part Name
Table 18
Part
Number
Quantity
Table 19
Tools Needed
Pressurizing Pump
Part
Number
Part Name
4C-6500
or
2F-7112
Digital Thermometer
or
Thermometer
Quantity
1
88
Testing and Adjusting Section
RENR1271-11
i01666401
Illustration 76
g01141597
Test location
(1) Plug
RENR1271-11
89
Testing and Adjusting Section
i01849228
Required Tools
Part
Number
Part Name
Quantity
6V-7775
8J-7844
Adapter Fitting
3K-0360
O-Ring Seal
5P-2725
164-2192
Pressure
5P-4487
Adapter
5P-2720
Probe Adapter
(1)
Probe(1)
Illustration 77
g00296313
90
Testing and Adjusting Section
RENR1271-11
Basic Engine
i01432013
Required Tools
Part
Number
Part Name
Quantity
1P-3537
Illustration 78
g00285686
RENR1271-11
91
Testing and Adjusting Section
i02281052
Flywheel - Inspect
Tools Needed
Part
Number
8T-5096
Part Name
Dial Indicator Gp
Quantity
1
g01141609
Illustration 80
Checking bore runout of the flywheel
(1)
(2)
(3)
(4)
7H-1945
7H-1645
7H-1942
7H-1940
Holding Rod
Holding Rod
Dial Indicator
Universal Attachment
g00286049
92
Testing and Adjusting Section
RENR1271-11
g00286058
Illustration 81
Flywheel clutch pilot bearing bore
Table 23
Tools Needed
8T-5096
Part Name
Dial Indicator Gp
Quantity
1
Illustration 82
8T-5096 Dial Indicator
g00285932
Part
Number
Illustration 83
g00285931
Illustration 84
8T-5096 Dial Indicator
g00285934
RENR1271-11
93
Testing and Adjusting Section
Illustration 85
g00285932
Illustration 87
g00286046
g00285936
(1)
(2)
(3)
(4)
94
Testing and Adjusting Section
RENR1271-11
i02487784
Illustration 88
g01124289
Adapter
Rubber
Damper assembly
Bolt
Crankshaft pulley
Illustration 89
g01124414
NOTICE
Inspect the viscous vibration damper for signs of leaking and for signs of damage to the case. Either of
these conditions can cause the weight to contact the
case. This contact can affect damper operation.
RENR1271-11
95
Testing and Adjusting Section
i01388616
g00295949
Crankshaft
Hub
Rubber
Ring
Alignment marks
Damaged
Bent
Worn bolt holes with loose fit for bolts
Crankshaft failure due to torsional forces
The rubber vibration damper displays alignment
marks on the hub and on the ring. These marks
indicate the condition of the rubber vibration damper.
96
Testing and Adjusting Section
RENR1271-11
Illustration 91
g00295962
Leaking
Damaged
Bent
Worn bolt holes with loose fit for bolts
Crankshaft failure due to torsional forces
NOTICE
Inspect the viscous vibration damper for signs of leaking and for signs of damage to the case. Either of
these conditions can cause the weight to contact the
case. This contact can affect damper operation.
RENR1271-11
97
Testing and Adjusting Section
Electrical System
i02482495
Battery - Test
SMCS Code: 1401-081
Most of the tests of the electrical system can be done
on the engine. The wiring insulation must be in good
condition. The wire and cable connections must be
clean, and both components must be tight.
Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operated. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Injury to personnel can be the result.
The battery circuit is an electrical load on the charging
unit. The load is variable because of the condition of
the charge in the battery.
NOTICE
The charging unit will be damaged if the connections
between the battery and the charging unit are broken
while the battery is being charged. Damage occurs
because the load from the battery is lost and because
there is an increase in charging voltage. High voltage
will damage the charging unit, the regulator, and other
electrical components.
Illustration 93
g00283565
Illustration 92
177-2330 Battery Analyzer
g00859857
98
Testing and Adjusting Section
RENR1271-11
i02482986
g01012117
Table 24
Tools Needed
Part
Number
Illustration 94
Part Name
Quantity
RENR1271-11
99
Testing and Adjusting Section
Table 25
Tools Needed
Part Number
237-5130
or
146-4080
Illustration 95
Part Name
Digital Multimeter
QTY
1
g00283566
Keyswitch
Starting motor solenoid
Starting motor
Illustration 96
g00283566
100
Testing and Adjusting Section
RENR1271-11
i01907823
Illustration 97
g00885031
Diagnostic module
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
4 Mounting holes
System status light
Over-pressure alarm light
Over-temp alarm light
System problem light
Alarm reset button
Pressure transducer port
Wire passage
Serial data comm port
RENR1271-11
101
Testing and Adjusting Section
Active alarm
Log the events that caused the alarm.
Output 1
Warning
Active alarm
Active alarm
Output 1
(continued)
Output 1
Active alarm
Table 26
Output 1
Output 1
Output turned on.
Activate the alarm when the
temperature is above 250 C (482 F)
for 10 minutes and the pressure does
not change by at least 1 in Hg.
(continued)
102
Testing and Adjusting Section
RENR1271-11
Active alarm
Log the events that caused the alarm.
Alarm for
negative
pressure
Output 1
Output turned on.
Activate the alarm when the
temperature is above 200 C (392 F)
for 1 minute and the pressure is less
than 1 in Hg.
i02237991
Illustration 99
g01097827
g01134792
Illustration 100
Connections for pinion clearance check
(4) Starting motor negative wire
g00716453
RENR1271-11
103
Testing and Adjusting Section
Illustration 101
g00716455
104
Index Section
RENR1271-11
Index
A
Aftercooler - Test ................................................... 69
Aftercooler Core Leakage .................................. 70
Air System Restriction........................................ 71
Dynamometer Test............................................. 72
Turbocharger Failure ......................................... 72
Visual Inspection................................................ 69
Air in Fuel - Test..................................................... 53
Air Inlet and Exhaust System .......................... 36, 62
Air Inlet Heater ................................................... 38
Turbocharger ..................................................... 37
Valve System Components................................ 38
Air Inlet and Exhaust System - Inspect.................. 62
Air Inlet Restriction............................................. 62
Exhaust Back Pressure...................................... 63
Exhaust Restriction ............................................ 63
B
Basic Engine.................................................... 45, 90
Camshaft............................................................ 47
Crankshaft.......................................................... 46
Cylinder Block And Head ................................... 45
Piston, Rings And Connecting Rods.................. 45
Vibration Damper ............................................... 47
Battery - Test ......................................................... 97
C
Charging System - Test ......................................... 98
Test Tools For The Charging System................. 98
Compression - Test................................................ 73
Connecting Rod Bearings - Inspect....................... 90
Cooling System ............................................... 42, 81
Coolant Conditioner (If Equipped)...................... 44
Coolant For Air Compressor (If Equipped)......... 44
Cooling System - Check (Overheating) ................. 81
Cooling System - Inspect....................................... 83
Cooling System - Test............................................ 84
Checking the Filler Cap...................................... 86
Making the Correct Antifreeze Mixtures............. 86
Test For The Water Temperature Gauge ........... 87
Test Tools For Cooling System .......................... 84
Testing The Radiator And Cooling System For
Leaks................................................................ 87
Cylinder Block - Inspect......................................... 90
E
Electric Starting System - Test............................... 99
RENR1271-11
105
Index Section
I
Important Safety Information ................................... 2
Increased Engine Oil Temperature - Inspect ......... 80
Inlet Manifold Pressure - Test ................................ 68
L
Lubrication System .......................................... 40, 76
M
Main Bearings - Inspect......................................... 90
P
Pinion Clearance - Adjust .................................... 102
Electric Starting Motor...................................... 102
Piston Ring Groove - Inspect................................. 90
S
Systems Operation Section ..................................... 4
T
Table of Contents..................................................... 3
Testing and Adjusting Section ............................... 52
Turbocharger - Inspect .......................................... 65
Inspection of the Compressor and the Compressor
Housing ............................................................ 66
Inspection of the Turbine Wheel and the Turbine
Housing ............................................................ 66
Inspection of the Wastegate .............................. 67
U
Unit Injector - Test.................................................. 60
V
Vibration Damper - Check ............................... 9495
Rubber Vibration Damper (If Equipped)....... 9495
Viscous Vibration Damper ................................. 96
Viscous Vibration Damper (If Equipped) ............ 94
106
Index Section
RENR1271-11
RENR1271-11
107
Index Section
2006 Caterpillar
All Rights Reserved
Printed in U.S.A.